Digitally signed by G

K Halder
DN: cn=G K Halder,
c=IN, o=Ntpc,
ou=Jajjar and Vallur
TForce,
email=gkhalder@ntpc
eoc.co.in
Date: 2010.03.12
10:10:07 +05'30'

BHARAT HEAVY ELECTRICALS LIMITED

ELECTRONICS DIVISION, MYSORE ROAD,
BANGALORE

PROJECT: VALLUR UNIT 1,2

NICAD BATTERY FOR 24V DC BATTERY
FOR TG CHARGER

DOCUMENTS FOR APPROVAL

GENERAL ARRANGEMENT DRAWINGS
BATTERY SIZING CALCULATION
LIST OF ACCESSORIES
CATALOGUE

NTPC Doc. No: 0260-110-04-EN-PVI-Y-004-02

HBL POWER SYSTEMS LIMITED

44, CENTRAL STREET, SHIVAJI NAGAR, BANGALORE
 INDEX

PROJECT : VALLUR UNIT # 1,2

PACKAGE : TG CHARGER.

SL.NO. DESCRIPTION NO OF SHEETS

A) BATTERY FOR TG MAIN CHARGER (BATTERY 20 KBH 670P- 2SETS/Unit)

1. General Arrangement Drawing 02

2. Battery sizing Calculations 05

3. Battery data sheet 01

4. List of Accessories for Battery per set 01

5. CATALOGUE 11

B) Document for Cell Booster & Discharge resistor for 670 Ah 18

VALLUR unit - 1 & 2

TG Main Charger batteries bill of material
I. TG Main package (Main) Unit - 1 Unit - 2
a) BATTERY FORTG MAIN CHARGER Qty Qty
1) 20 Cells of 670 Ah (KBH 670P) Battery 2 sets 2 sets
2) Battery Accessories 2 sets 2 sets
3) Cell Booster (12V-105A) 1 No 1 No
4) Battery discharge resistor bank (20V-35V,135 A) 1 No 1 No
5) Copper Termination Plates (with Adequate support 2 sets 2 sets
arrangement)for each of +ve/-ve poles to cater to 3
runs of 1C x 630 sqmm Al cable
6) Battery Stand of teak wood with epoxy anti alkaline 2 sets 2 sets
corrosive paint of shade RAL 9002
SIZING/BHEL/NTPC/DOM-2984

HBL
HBLPOWER
POWERSYSTEMS
SYSTEMSLTD.
LTD.
BATTERY CALCULATION REPORT : IEEE 1115 - 2000
CUSTOMER BHARAT HEAVY ELECTRICALS LIMITED PI.NO 6843/NCD
PROJECT VALLUR UNIT 1,2 DATE 22.10.2009
PACKAGE TG CHARGER REVISION 0

A.) BATTERY FOR TG CHARGER

NOMINAL SYSTEM VOLTAGE : 24 V DC

MIN. DC VOLTAGE : 21.75 V (Specified)

MAX. DC VOLTAGE : 28.0 V (Specified)

END CELL VOLTAGE : 1.14 V (Specified)

CABLE VOLTAGE DROP : 1.05 V (Specified)

NUMBER OF CELLS : (Min. DC Voltage + Cable drop) / ECV

(21.75 + 1.05) / 1.14 = 20 Nos.

MINIMUM OPERATING TEMP. : 4 degree C (Specified)

DUTY CYCLE : 362 Amps for 1 hr.

AGING FACTOR : 0.8 (Specified)

Duration K - Factor Temperat Corrected

(Ah/A) ure K - Factor
derating
Factor
1 hr. 1.235 0.908 1.36

(1) (2) (3) (4) (5) (6) (7)

PERIOD LOAD CHANGE IN LOAD DURATION TIME TO END CAPACITY REQUIRED SECTION
(AMPS.) (AMPERES) OF PERIOD SECTION RATING (3) X (6)
(MINUTES) (MINUTES) FACTOR AT RATED AMP HRS
t MIN.RATE
(Kt)
POS. NEG.
VALUE VALUE
SECTION - 1 FOR FIRST PERIOD ONLY - IF A2 > A1 GO TO SECTION 2
1 A1= 362 A1-0 = 362 M1 = 60 T=M1= 60 minutes. 1.36 492.32 0.00
minutes
SECTION-1 SUB TOTAL AH 492.32 0.00
TOTAL AH 492.32

MIN. CAPACITY REQUIRED. : 492.32

BY APPLYING AGING FACTOR : 615.4

BY APPLYING FLOAT CHARGE FACTOR : 634.43

CELL SELECTED : KBH 670 P

BATTERY BEING OFFERED : 20 KBH 670 P-----2 SETS OF BATTERY PER UNIT

The battery chosen is suitable for 380A also to take care of any contigency or exigency which may creep in
later.



 

   
 
    



 
  

 
 
 

 
 

 
 



         

                  
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REDUCTION FACTORS FOR CONSTANT VOLTAGE CHARGING KPH / KBH TYPE
CELLS TO BE APPLIED ON THE CURRENT DATA OF CONSTANT CURRENT
CHARGING

DISCHARGE
TIME 1 1.05 1.1 1.14
1 Sec 1 0.880 0.850 0.800 0.760
5 Sec 5 0.880 0.850 0.800 0.760
10 Sec 10 0.880 0.850 0.800 0.760
15 Sec 15 0.880 0.850 0.800 0.760
20 Sec 20 0.880 0.850 0.800 0.760
30 Sec 30 0.880 0.850 0.800 0.760
40 Sec 40 0.880 0.850 0.800 0.760
50 Sec 50 0.890 0.850 0.810 0.760
60 Sec 60 0.890 0.850 0.820 0.770
90 Sec 90 0.900 0.860 0.830 0.780
2 Min 120 0.900 0.870 0.840 0.790
3 Min 180 0.920 0.880 0.850 0.800
4 Min 240 0.930 0.890 0.870 0.810
5 Min 300 0.940 0.900 0.880 0.820
6 Min 360 0.950 0.910 0.890 0.830
7 Min 420 0.960 0.920 0.900 0.840
8 Min 480 0.970 0.930 0.910 0.850
9 Min 540 0.980 0.940 0.920 0.860
10 Min 600 1.000 0.950 0.930 0.870
15 Min 900 1.000 0.970 0.950 0.880
20 Min 1200 1.000 0.970 0.950 0.890
25 Min 1500 1.000 1.000 0.960 0.900
30 Min 1800 1.000 1.000 0.970 0.910
35 Min 2100 1.000 1.000 0.980 0.920
40 Min 2400 1.000 1.000 0.990 0.930
45 Min 2700 1.000 1.000 1.000 0.940
50 Min 3000 1.000 1.000 1.000 0.950
55 Min 3300 1.000 1.000 1.000 0.960
60 Min 3600 1.000 1.000 1.000 0.970
90 Min 5400 1.000 1.000 1.000 1.000
2 Hrs 7200 1.000 1.000 1.000 1.000
2.5 Hrs 9000 1.000 1.000 1.000 1.000
3 Hrs 10800 1.000 1.000 1.000 1.000
3.5 Hrs 12600 1.000 1.000 1.000 1.000
4 Hrs 14400 1.000 1.000 1.000 1.000
4.5 Hrs 16200 1.000 1.000 1.000 1.000
5 Hrs 18000 1.000 1.000 1.000 1.000
 Float Charge Factor Curve
1.000

1.00 V

1.05 V
0.900

1.10 V
ell voltage

1.14 V
0.800
End Ce

0.700

0.600

Time (In Seconds)

1 1.05 1.1 1.14

6843 / DS / 20 KBH 670P Rev. 0, Dt.22.10.2009

TECHNICAL DATA SHEET FOR TG CHARGER Ni-Cd BATTERY

1.00.00 Manufacturer HBL Power Systems

Ltd.
2.00.00 Type of Battery Nickel Cadmium Pocket
Plate Battery – 20
KBH 670P
3.00.00 Guaranteed AH capacity at 5 hours discharge 670 Ah
rate
4.00.00 AH capacity at half hour discharge rate to 1.00 v 571.5 Ah **
per cell for Ni-Cad battery at ambient of 27 deg.
C
5.00.00 Open circuit voltage of cell when completely
discharge at 27 deg. C
a) At 10 hour discharge rate ------------
b) At 1 hour discharge rate 1.29 v/cell
c) At 5 hour discharge rate 1.26 v/cell
6.00.00 No. of cells/battery 20 Nos.
7.00.00 Applicable standards IS 10918 / IEC 60623
8.00.00 Average life in years 20 Years
9.00.00 a) Recommended range of floating / trickle 1.40 – 1.42 v/cell
charging
b) Recommended range of charging 1.53 – 1.67 v/cell
voltage
10.00.00 a) Trickel charging current 1-2 mA/Ah
b) Boost charging current 0.2 C5 A for 8 hours.
c) Internal resistance of cell < 0.08 m ohms
11.00.00 Containers
a) Type Translucent
b) Material Polypropylene
12.00.00 Maximum electrolyte temperature that cell can 50 deg. C
withstand continuously without injurious effects
13.00.00 Catalogue attached. Yes
14.00.00 All types test reports enclosed. No
15.00.00 Rack dimension 2050 ±20L x 596 ±15W x
1550 ±15H
16.00.00 Type of Rack 1 step 2 tier (Teak
wood)
17.00.00 Racks per Battery 1 No.

** The capacity of the 670 Ah battery at ½ hour discharge rate is obtained

by multiplying the discharge current at ½ hour discharge to ECV of 1.00 Volt
per cell ( 1143 Amps) by 0.5 hours, which is 571.5Ah.

SHEET 1 OF 1
 TECHNICAL DATA SHEET PI.No 6843/NCD
Custom er M /S.Bharat Heavy Electricals Ltd. Date 22.10.2009
Project VALLUR UNIT 1,2
Rev 0
Package TG CHARGER
HBL POWER SYSTEMS LTD. Page 1 of1

LIST OF ACCESSORIES FOR NICAD BATTERY PER UNIT

i Set of spanners 5 nos

ii Topping Bottle 2 nos.
iii Alkali mixing jar 5 nos
iv Funnel 5 nos
v Pair of Rubber gloves 5 nos
vi Maintenance manual 3 nos
vii Cell testing voltmeter 5 nos
viii Thermometer 5 nos
ix Hydrometer 5 nos
x Rubber Apron 5 nos
xi Petroleum jelly 1 Box
xii Specific gravity correction chart Not required for NICAD battery.
xiii No smoking notice 5 nos.
xiv Industrial goggles 5 nos
xv Min. & Max Temperature detector 1 no
xvi Instruction card 10 nos
xvii Wall mounting holder made of teakwood for 5 nos
hydrometer & thermometer

xviii Set of hydrometer syringes suitable for the vent 5 nos

holes in different cells

xix Cell lifting facility 1 no

xx Assembly Wrenches 2 nos.
xxi Inter-row connectors (with 10 % spare) 2 nos.
xxii Inter-cell connectors (with 10 % spare) 2 nos.
Electrolyte in non-returnable cans (as per std) with
xxiii 10 % extra 1 Lot
NCPP
Nickel Cadmium Pocket Plate Batteries

Block Battery
Dimensional and Electrical Data
 Nickel Cadmium Pocket Plate Batteries

HBL's Nickel Cadmium Pocket Plate Battery

designs are based on the superior Pocket Plate
technology of SABNIFE AB, Sweden.

The first electrode design for Nickel Cadmium

Batteries employed the pocket plate
construction which is still considered to be the
most reliable design. IEC/EN 60623

The fully integrated modern factory, supported

by strong process management and quality
controls makes HBL one of the best Nickel
Cadmium Battery production facilities in the
world.

HBL’s NCPP Block Batteries are available as

Blocks (of individual cells thermally welded
together) of multiple voltages & capacities.

Designed to perfection, built to last

The Superior constructional features of the HBL’s
Nickel Cadmium Pocket Plate Battery, makes it a reliable product for any application

Construction

Splash guard
Prevents electrolyte splashing and possible short-circuit
Flame Arresting Vent caused by external objects accidentally falling into the cell
Prevents explosion & electrolyte contamination

Plate Groups
Welded construction imparts high mechanical strength
to withstand severe vibrations
Terminal Arrangement
Nickel-plated terminal posts provide good
electrical conductivity
Plate
Made of Double perforated steel strips, encompass the
active materials

Polypropylene Grid Separator

Separates the plates and insulate the frames Translucent polypropylene container
from each other and allows free electrolyte flow Fusion welded to lids, makes the cell mechanically
sturdy and facilitates visual electrolyte level inspection
 Product Range
HBL’s NCPP Block Batteries are available in three types designated KBH, KBM & KBL based on performance
characteristics. The wide capacity range in each type permit selection of an optimum battery for any
application.

KBH Range KBM Range KBL Range

Thin plates Optimised plate Thick plates

thickness
Greatest Plate area Greatest amount of
per amount of active Balance between active material per
material High Rate and Low plate area
Rate
High Performance Low currents for long
for short discharge Ideal for medium discharge times
times discharge times

Outstanding Advantages of HBL’s batteries are:

Highest reliability among all battery systems. Operation over a wide temperature range.

Unsurpassed resistance to electrical and Minimal maintenance.

mechanical abuse.
Long shelf life.
Long service life.
Quick charging.
Very good charge retention.

Built in Reliability
In the Pocket Plate Design, the Active materials are
encapsulated between folded steel strips which are perforated
from both sides. This double perforation method increases the
effective surface area by 30% and helps in better utilization of
the active material thereby making the battery more efficient.
The folded steel strips are pressed into a frame; the alkaline
electrolyte reacts only with the Active Materials and not with
the steel structure, so there is no chance of internal mechanical
failure. This makes the battery strong enough to withstand
s h o c k o r v i b r a t i o n .

The pocket plate group separators are made of a wear

resistant polypropylene / ABS material which is
chemically inert. These cells are available in containers
of polypropylene. The polypropylene container can
withstand mechanical stresses, shocks and vibrations.
It performs in temperature extremes without losing
strength, insulates well, resists corrosion. Furthermore,
the translucent nature of polypropylene allows visual
check of electrolyte level for ease of maintenance. The
cells are also available in Structural Foam molded, Stainless
Steel containers for special requirements.

The above design features make these batteries rugged and

highly reliable.

01
Governing Standards

HBL’s NCPP batteries conform to relevant international standards such as IEC, DIN, BS, KS, etc. The Batteries are
tested and certified by INTERTEK ETL SEMKO for IEC 60623 standards.

Battery Characteristics
Nickel Cadmium pocket plate batteries are the most reliable and rugged batteries available today. They can
withstand to a great extent any type of abuse like overcharge, deep discharge, even accidental reverse charge and
can be stored in any state of charge.

Charging
These batteries can be charged by all normal methods (like taper, constant current, constant voltage, float or trickle
charging. A Dual mode charger which will recharge a discharged battery in Boost mode (higher voltage and current)
and then bring it to Float mode (lower voltage) to keep it in fully charged condition is ideal to get the best
performance.

Current limit - max. 0.2C5 A

Float voltage - 1.40 to 1.42 V/Cell
However, if single mode charger is already available, like in old systems or in locomotives, the battery can
be operated with constant voltage charging.
Recommended Charging voltage setting: 1.45 to 1.50V / Cell.

Discharge Performance
The rated capacity of a Nickel Cadmium battery is defined as the Ampere Hours available at 5 hour rate of discharge
to an end voltage of 1.00V/Cell at 20 C after charging at constant current of 0.2C5 rate for 8 hours. The nominal
0

voltage of a single cell is 1.2 volts.

The discharge performance depends on the battery type. For example, a H type cell at 15 minutes discharge can
deliver about twice the discharge current compared to an L type cell of equal rated capacity.

Always use the discharge performance tables to find the proper H, M and L type alternatives for a specific
application.

The tabulated discharge performance data are valid for cells fully charged. Discharge performance data after long
term float with Constant Voltage is also provided.

If the actual conditions differ from standard, the expected performance will be different. Our application
engineering department will provide the details and further help you in selecting the optimum battery type for your
requirement.

In accordance with its policy of continuous improvement the company reserves the right to change specifications and designs
without notice. Illustrations,data, dimensions and weights given in this brochure are for guidance only.

02
H Range
Cell dimensions

Cell Dimensions in mm
Capacity
at the Length Cell Container Reserve Approx
Cell Type 5 hr rate connection size electrolyte Weight(Kg)
(Ah) Height Width
1.2 V 2.4 V 3.6 V bolt size reference cc/cell 1.2 V Block
L (1) L (2) L (3)
KBH 9 P 9 264 123 69 100 M8 B21-1 90 1.1
KBH 13 P 13 264 123 79 115 M8 B22-1 110 1.5
KBH 17 P 17 264 123 79 115 M8 B22-1 110 1.9
KBH 20 P 20 264 123 103 151 M8 B23-1 145 2.6
KBH 28 P 28 264 123 127 187 M8 B24-1 185 3.3
KBH 34 P 34 264 123 127 187 M8 B24-1 185 3.8
KBH 40 P 40 405 195 79 115 M10 B45-1 280 4.8
KBH 50 P 50 405 195 79 115 M10 B45-1 280 5.4
KBH 54 P 54 349 195 103 151 M10 B33-1 380 5.5
KBH 59 P 59 349 195 103 151 M10 B33-1 380 5.6
KBH 64 P 64 349 195 127 187 M10 B32-1 515 6.0
KBH 69 P 69 349 195 127 187 M10 B32-1 515 6.2
KBH 79 P 79 349 195 127 187 M10 B32-1 515 6.8
KBH 88 P 88 349 195 159 232 M10 B31B-1 650 7.8
KBH 98 P 98 349 195 159 232 M10 B31B-1 650 8.4
KBH 103 P 103 349 195 159 232 M10 B31B-1 650 9.4
KBH 110 P 110 349 195 183 268 M10 B31-1 745 9.5
KBH 118 P 118 349 195 183 268 M10 B31-1 745 9.6
KBH 127 P 127 349 195 132 252 372 2 x M10 B32-2 1030 11.0
KBH 137 P 137 349 195 132 252 372 2 x M10 B32-2 1030 12.0
KBH 140 P 140 349 195 132 252 372 2 x M10 B32-2 1030 12.3
KBH 157 P 157 349 195 132 252 372 2 x M10 B32-2 1030 13.4
KBH 170 P 170 349 195 132 252 372 2 x M10 B32-2 1030 14.5
KBH 177 P 177 349 195 159 2 x M10 B31B-2 1300 15.6
KBH 185 P 185 349 195 159 2 x M10 B31B-2 1300 16.1
KBH 196 P 196 349 195 159 2 x M10 B31B-2 1300 16.8
KBH 206 P 206 349 195 159 2 x M10 B31B-2 1300 17.4
KBH 218 P 218 349 195 183 2 x M10 B31-2 1490 18.6
KBH 236 P 236 349 195 183 2 x M10 B31-2 1490 19.6
KBH 245 P 245 349 195 183 2 x M10 B31-2 1490 20.0
KBH 265 P 265 349 195 232 3 x M10 B31B-3 1950 23.4
KBH 275 P 275 349 195 232 3 x M10 B31B-3 1950 24.0
KBH 294 P 294 349 195 232 3 x M10 B31B-3 1950 25.2
KBH 310 P 310 349 195 232 3 x M10 B31B-3 1950 26.0
KBH 330 P 330 349 195 268 3 x M10 B31-3 2235 26.7
KBH 353 P 353 349 195 268 3 x M10 B31-3 2235 28.0
KBH 362 P 362 349 195 268 3 x M10 B31-3 2235 28.9
KBH 393 P 393 349 195 304 4 x M10 B31B-4 2600 33.6
KBH 410 P 410 349 195 304 4 x M10 B31B-4 2600 34.0
KBH 420 P 420 349 195 352 4 x M10 B31-4 2980 36.0
KBH 445 P 445 349 195 352 4 x M10 B31-4 2980 36.8
KBH 471 P 471 349 195 352 4 x M10 B31-4 2980 38.0
KBH 481 P 481 349 195 352 4 x M10 B31-4 2980 38.5
KBH 491 P 491 349 195 377 5 x M10 B31B-5 3250 41.8
KBH 515 P 515 349 195 377 5 x M10 B31B-5 3250 43.0
KBH 530 P 530 349 195 437 5 x M10 B31-5 3725 47.0
KBH 545 P 545 349 195 437 5 x M10 B31-5 3725 47.5
KBH 570 P 570 349 195 437 5 x M10 B31-5 3725 48.0
KBH 590 P 590 349 195 437 5 x M10 B31-5 3725 48.5
KBH 615 P 615 405 195 377 5 x M10 B41B-5 3250 49.8
KBH 640 P 640 405 195 377 5 x M10 B41B-5 3250 51.0
KBH 670 P 670 405 195 377 5 x M10 B41B-5 3250 52.5
KBH 695 P 695 405 195 437 5 x M10 B41-5 3725 54.8
KBH 705 P 705 405 195 437 5 x M10 B41-5 3725 55.2
KBH 725 P 725 405 195 437 5 x M10 B41-5 3725 56.3
KBH 765 P 765 405 195 437 5 x M10 B41-5 3725 58.5
KBH 805 P 805 405 195 522 6 x M10 B41-6 4470 64.0
KBH 840 P 840 405 195 522 6 x M10 B41-6 4470 65.5
KBH 860 P 860 405 195 522 6 x M10 B41-6 4470 66.5
KBH 890 P 890 405 195 522 6 x M10 B41-6 4470 67.7
KBH 920 P 920 405 195 522 6 x M10 B41-6 4470 69.3
KBH 930 P 930 405 195 522 6 x M10 B41-6 4470 69.5

v Block types starting from KBH 88 P shall have handles.

v Cell ranges other than listed above can be supplied on request. The Parameters and performance will proportionately change.

03
Cell Performance H range
Performance fully charged with constant current charging
Final Voltage: 1.14 V/cell
Available amperes at +20º C ± 5º C

Hours Minutes Seconds

Cell Type C5 Ah
8 5 3 2 1.5 1 30 20 15 10 5 60 30 5 1

KBH 9 P 9 1.07 1.67 2.72 3.99 5.16 7.29 10.9 13.3 15.0 17.6 22.3 35.1 40.7 50.8 53.3
KBH 13 P 13 1.55 2.41 3.93 5.76 7.45 10.5 15.7 19.2 21.7 25.4 32.2 50.7 58.8 73.3 77.0
KBH 17 P 17 2.02 3.15 5.14 7.53 9.74 13.8 20.6 25.1 28.4 33.3 42.2 66.3 76.9 95.9 101
KBH 20 P 20 2.38 3.71 6.05 8.86 11.5 16.2 24.2 29.6 33.4 39.1 49.6 78.0 90.5 113 118
KBH 28 P 28 3.33 5.19 8.47 12.4 16.0 22.7 33.9 41.4 46.7 54.8 69.4 109 127 158 166
KBH 34 P 34 4.05 6.31 10.3 15.1 19.5 27.5 41.1 50.2 56.8 66.5 84.3 133 154 192 201
KBH 40 P 40 4.76 7.56 12.2 17.7 22.9 32.0 47.1 57.4 64.4 74.5 94.2 142 163 192 198
KBH 50 P 50 5.95 9.45 15.2 22.1 28.6 40.0 58.9 71.8 80.5 93.1 118 178 204 240 248
KBH 54 P 54 6.43 10.2 16.5 23.9 30.9 43.7 65.3 79.9 90.2 106 134 211 244 305 320
KBH 59 P 59 7.02 11.2 18.0 26.2 33.8 47.8 71.4 87.3 98.5 115 146 230 267 333 350
KBH 64 P 64 7.62 12.1 19.5 28.4 36.6 51.8 77.4 94.7 107 125 159 250 290 361 379
KBH 69 P 69 8.21 13.0 21.0 30.6 39.5 55.9 83.5 102 115 135 171 269 312 389 409
KBH 79 P 79 9.40 14.9 24.1 35.0 45.3 64.0 95.6 117 132 155 196 308 357 446 468
KBH 88 P 88 10.5 16.6 26.8 39.0 50.4 71.3 107 130 147 172 218 343 398 496 521
KBH 98 P 98 11.7 18.5 29.9 43.5 56.2 79.4 119 145 164 192 243 382 443 553 581
KBH 103 P 103 12.3 19.5 31.4 45.7 59.0 83.4 125 152 172 202 255 402 466 581 610
KBH 110 P 110 13.1 20.8 33.5 48.8 63.0 89.1 133 163 184 215 273 429 498 620 652
KBH 118 P 118 14.0 22.3 36.0 52.3 67.6 95.6 143 175 197 231 293 460 534 666 699
KBH 127 P 127 15.1 24.0 38.7 56.3 72.7 103 154 188 212 249 315 495 575 716 752
KBH 137 P 137 16.3 25.9 41.8 60.8 78.4 111 166 203 229 268 340 534 620 773 812
KBH 140 P 140 16.7 26.5 42.7 62.1 80.2 113 169 207 234 274 347 546 633 790 829
KBH 157 P 157 18.7 29.7 47.9 69.6 89.9 127 190 232 262 307 389 612 710 886 930
KBH 170 P 170 20.2 32.1 51.8 75.4 97.3 138 206 251 284 333 421 663 769 959 1007
KBH 177 P 177 21.1 33.5 54.0 78.5 101 143 214 262 295 346 439 690 801 998 1049
KBH 185 P 185 22.0 35.0 56.4 82.0 106 150 224 274 309 362 458 722 837 1043 1096
KBH 196 P 196 23.3 37.0 59.8 86.9 112 159 237 290 327 384 486 764 887 1105 1161
KBH 206 P 206 24.5 38.9 62.8 91.4 118 167 249 305 344 403 510 803 932 1162 1220
KBH 218 P 218 25.9 41.2 66.5 96.7 125 177 264 322 364 427 540 850 986 1230 1291
KBH 236 P 236 28.1 44.6 72.0 105 135 191 286 349 394 462 585 920 1068 1331 1398
KBH 245 P 245 29.2 46.3 74.7 109 140 198 296 362 409 479 607 956 1109 1382 1451
KBH 265 P 265 31.5 50.1 80.8 118 152 215 321 392 442 519 657 1034 1199 1495 1570
KBH 275 P 275 32.7 52.0 83.9 122 157 223 333 407 459 538 681 1073 1244 1551 1629
KBH 294 P 294 35.0 55.6 89.7 130 168 238 356 435 491 575 729 1147 1330 1658 1742
KBH 310 P 310 36.9 58.6 94.5 137 177 251 375 459 518 607 768 1209 1403 1748 1836
KBH 330 P 330 39.3 62.4 101 146 189 267 399 488 551 646 818 1287 1493 1861 1955
KBH 353 P 353 42.0 66.7 108 157 202 286 427 522 589 691 875 1377 1597 1991 2091
KBH 362 P 362 43.1 68.4 110 161 207 293 438 536 604 708 897 1412 1638 2042 2145
KBH 393 P 393 46.8 74.3 120 174 225 318 476 581 656 769 975 1533 1778 2217 2328
KBH 410 P 410 48.8 77.5 125 182 235 332 496 607 684 802 1016 1599 1855 2312 2429
KBH 420 P 420 50.0 79.4 128 186 240 340 508 621 701 822 1041 1638 1900 2369 2488
KBH 445 P 445 53.0 84.1 136 197 255 360 538 658 743 871 1103 1736 2014 2510 2636
KBH 471 P 471 56.0 89.0 144 209 270 382 570 697 786 922 1168 1837 2131 2657 2790
KBH 481 P 481 57.2 90.9 147 213 275 390 582 712 803 941 1192 1876 2176 2713 2850
KBH 491 P 491 58.4 92.8 150 218 281 398 594 726 820 961 1218 1915 2222 2769 2909
KBH 515 P 515 61.3 97.3 157 228 295 417 623 762 860 1008 1276 2009 2330 2905 3051
KBH 530 P 530 63.1 100 162 235 303 429 641 784 885 1037 1313 2067 2398 2989 3140
KBH 545 P 545 64.9 103 166 242 312 441 659 806 910 1067 1350 2126 2466 3074 3229
KBH 570 P 570 67.8 108 174 253 326 462 690 843 952 1115 1412 2223 2579 3215 3377
KBH 590 P 590 70.2 112 180 262 338 478 714 873 985 1155 1463 2301 2670 3328 3495
KBH 615 P 615 73.2 116 188 272 352 492 724 883 990 1146 1448 2184 2496 2948 3051
KBH 640 P 640 76.2 121 195 283 366 512 757 919 1030 1192 1507 2273 2606 3068 3175
KBH 670 P 670 79.7 127 204 296 383 536 793 962 1078 1248 1578 2380 2728 3212 3323
KBH 695 P 695 82.7 131 212 307 398 556 822 998 1118 1295 1636 2468 2830 3332 3447
KBH 705 P 705 83.9 133 215 312 403 564 834 1012 1134 1313 1660 2504 2871 3380 3497
KBH 725 P 725 86.3 137 221 320 415 580 858 1041 1167 1351 1707 2575 2952 3476 3596
KBH 765 P 765 91.0 145 233 338 438 612 905 1098 1231 1425 1801 2717 3115 3667 3795
KBH 805 P 805 95.8 152 246 356 460 644 953 1156 1295 1500 1895 2859 3278 3859 3993
KBH 840 P 840 100 159 256 371 480 672 994 1206 1352 1565 1978 2983 3420 4027 4167
KBH 860 P 860 102 163 262 380 492 688 1018 1235 1384 1602 2025 3054 3502 4123 4266
KBH 890 P 890 106 168 271 393 509 712 1053 1278 1433 1658 2097 3161 3624 4267 4415
KBH 920 P 920 109 174 281 407 526 736 1089 1321 1481 1714 2167 3267 3746 4410 4563
KBH 930 P 930 111 176 284 411 532 744 1101 1335 1496 1732 2191 3303 3787 4458 4613

04
Cell Performance H range
Performance fully charged with constant current charging
Final Voltage: 1.00 V/cell
Available amperes at +20º C ± 5º C

Hours Minutes Seconds

Cell Type C5 Ah
8 5 3 2 1.5 1 30 20 15 10 5 60 30 5 1

KBH 9 P 9 1.14 1.80 2.96 4.40 5.79 8.47 15.5 20.9 24.5 29.1 37.0 55.3 63.1 79.4 87.1
KBH 13 P 13 1.64 2.60 4.28 6.35 8.36 12.2 22.4 30.1 35.4 42.0 53.5 79.9 91.2 115 126
KBH 17 P 17 2.15 3.40 5.59 8.30 10.9 16.0 29.3 39.4 46.3 54.9 70.0 105 119 150 165
KBH 20 P 20 2.52 4.00 6.58 9.77 12.9 18.8 34.5 46.4 54.5 64.6 82.3 123 140 177 194
KBH 28 P 28 3.53 5.60 9.21 13.7 18.0 26.3 48.3 64.9 76.3 90.5 115 172 196 247 271
KBH 34 P 34 4.29 6.80 11.2 16.6 21.9 32.0 58.6 78.8 92.6 110 140 209 238 300 329
KBH 40 P 40 5.05 8.00 13.2 19.5 25.7 37.6 68.2 91.8 106 125 156 225 254 309 329
KBH 50 P 50 6.31 10.00 16.5 24.4 32.1 47.0 85.3 115 133 156 195 281 318 386 411
KBH 54 P 54 6.82 10.8 17.8 26.4 34.7 50.8 93.1 125 147 175 222 332 379 477 523
KBH 59 P 59 7.45 11.8 19.5 28.8 38.0 55.5 102 137 161 191 243 363 414 521 571
KBH 64 P 64 8.08 12.8 21.1 31.3 41.2 60.2 110 148 174 207 263 393 449 565 620
KBH 69 P 69 8.71 13.8 22.8 33.7 44.4 64.9 119 160 188 223 284 424 484 609 668
KBH 79 P 79 9.97 15.8 26.1 38.6 50.8 74.3 136 183 215 255 325 486 554 697 765
KBH 88 P 88 11.1 17.6 29.1 43.0 56.6 82.8 152 204 240 284 362 541 617 777 852
KBH 98 P 98 12.4 19.6 32.4 47.9 63.1 92.2 169 227 267 317 403 602 687 865 949
KBH 103 P 103 13.0 20.6 34.0 50.3 66.3 96.9 178 239 281 333 424 633 722 909 997
KBH 110 P 110 13.9 22.0 36.3 53.7 70.8 103 190 255 300 356 453 676 771 971 1065
KBH 118 P 118 14.9 23.6 39.0 57.6 75.9 111 204 274 322 381 486 725 827 1041 1142
KBH 127 P 127 16.0 25.4 41.9 62.0 81.7 119 219 294 346 410 523 781 891 1121 1229
KBH 137 P 137 17.3 27.4 45.2 66.9 88.2 129 236 318 373 443 564 842 961 1209 1326
KBH 140 P 140 17.7 28.0 46.2 68.4 90.1 132 241 325 381 452 576 860 982 1236 1355
KBH 157 P 157 19.8 31.4 51.8 76.7 101 148 271 364 428 507 646 965 1101 1386 1520
KBH 170 P 170 21.5 34.0 56.1 83.0 109 160 293 394 463 549 700 1045 1192 1500 1646
KBH 177 P 177 22.3 35.4 58.4 86.4 114 166 305 411 482 572 729 1088 1241 1562 1713
KBH 185 P 185 23.4 37.0 61.1 90.4 119 174 319 429 504 598 761 1137 1297 1633 1791
KBH 196 P 196 24.7 39.2 64.7 95.7 126 184 338 455 534 633 807 1205 1374 1730 1897
KBH 206 P 206 26.0 41.2 68.0 101 133 194 355 478 561 666 848 1266 1445 1818 1994
KBH 218 P 218 27.5 43.6 72.0 106 140 205 376 505 594 705 897 1340 1529 1924 2110
KBH 236 P 236 29.8 47.2 77.9 115 152 222 407 548 643 763 972 1451 1655 2083 2285
KBH 245 P 245 30.9 49.0 80.9 120 158 230 423 568 668 792 1008 1506 1718 2162 2372
KBH 265 P 265 33.5 53.0 87.5 129 171 249 457 615 722 856 1091 1629 1858 2339 2565
KBH 275 P 275 34.7 55.0 90.8 134 177 259 474 638 749 889 1132 1690 1928 2427 2662
KBH 294 P 294 37.1 58.8 97.1 144 189 277 507 682 801 950 1210 1807 2062 2595 2846
KBH 310 P 310 39.1 62.0 102 151 199 292 535 719 845 1002 1276 1905 2174 2736 3001
KBH 330 P 330 41.7 66.0 109 161 212 310 569 765 899 1067 1358 2028 2314 2913 3195
KBH 353 P 353 44.6 70.6 117 172 227 332 609 820 962 1141 1453 2170 2475 3116 3417
KBH 362 P 362 45.7 72.4 120 177 233 340 624 839 986 1170 1490 2225 2539 3195 3504
KBH 393 P 393 49.6 78.6 130 192 253 370 678 912 1071 1270 1618 2415 2756 3469 3804
KBH 410 P 410 51.8 82.0 135 200 264 386 707 951 1117 1325 1687 2520 2875 3619 3969
KBH 420 P 420 53.0 84.0 139 205 270 395 724 974 1144 1357 1728 2581 2945 3707 4066
KBH 445 P 445 56.2 89.0 147 217 286 419 768 1032 1213 1438 1831 2735 3121 3928 4308
KBH 471 P 471 59.5 94.2 155 230 303 443 812 1093 1283 1522 1939 2895 3303 4157 4560
KBH 481 P 481 60.7 96.2 159 235 310 452 830 1115 1311 1555 1979 2956 3373 4245 4656
KBH 491 P 491 62.0 98.2 162 240 316 462 847 1139 1338 1587 2021 3018 3443 4334 4753
KBH 515 P 515 65.0 103 170 252 331 484 888 1194 1403 1665 2119 3165 3612 4545 4985
KBH 530 P 530 66.9 106 175 259 341 498 914 1229 1444 1713 2181 3258 3717 4678 5131
KBH 545 P 545 68.8 109 180 266 351 513 940 1264 1485 1761 2243 3350 3822 4810 5276
KBH 570 P 570 72.0 114 188 278 367 536 983 1322 1553 1842 2346 3503 3997 5031 5518
KBH 590 P 590 74.5 118 195 288 380 555 1018 1369 1608 1907 2430 3626 4137 5207 5712
KBH 615 P 615 77.6 123 203 300 395 578 1049 1411 1628 1917 2394 3461 3907 4753 5053
KBH 640 P 640 80.8 128 211 312 411 602 1092 1468 1699 1997 2491 3602 4066 4946 5259
KBH 670 P 670 84.6 134 221 327 430 630 1143 1537 1779 2090 2608 3770 4257 5178 5505
KBH 695 P 695 87.7 139 229 339 446 653 1186 1594 1845 2168 2705 3911 4416 5371 5711
KBH 705 P 705 89.0 141 232 344 453 663 1203 1617 1872 2200 2744 3967 4479 5448 5793
KBH 725 P 725 91.5 145 239 354 466 682 1237 1663 1925 2262 2822 4080 4606 5603 5957
KBH 765 P 765 96.6 153 252 373 491 719 1305 1755 2031 2387 2978 4305 4860 5912 6286
KBH 805 P 805 102 161 265 393 517 757 1373 1847 2138 2512 3134 4530 5114 6221 6615
KBH 840 P 840 106 168 277 410 539 790 1433 1927 2230 2621 3270 4727 5337 6491 6902
KBH 860 P 860 109 172 284 420 552 809 1467 1973 2284 2683 3348 4840 5464 6646 7067
KBH 890 P 890 112 178 293 435 572 837 1518 2042 2363 2777 3464 5008 5654 6878 7313
KBH 920 P 920 116 184 303 449 591 865 1569 2111 2443 2871 3581 5177 5845 7110 7560
KBH 930 P 930 117 186 307 454 597 874 1586 2134 2469 2902 3620 5234 5909 7187 7642

07
 SINGLE TIER RACKS
BATTERY RACK DIMENSIONS 2STEP 1TIER RACK

For safe and reliable operation, batteries should be mounted on suitable battery racks.
HBL battery racks are made of alkali-resistant, powder coated steel sections. Battery
racks are available in multi-step one tier or multi-step two tier configuration. Standard battery
racks are supplied in knocked-down condition and can be easily assembled at site.

Container 1Tier 2Tier

size
reference 1STEP 2STEP 3STEP 4STEP 1STEP 2STEP 3STEP 4STEP

W H W H W H W H W H W H W H W H
(Normal arrangement)
B21-1/B22-1
296 703 434 818 572 933 296 1250 434 1450 572 1700
B23-1/B24-1
B31-1/B31B-1
440 788 650 903 860 1018 440 1400 650 1620 860 1850
B32-1/B33-1
B41-1/B41B-1
B42-1/B42A-1 440 844 650 959 860 1074 440 1550 650 1800 860 2050
B44-1/B45-1
(Cross-wise arrangement)
B31-2 416 788 614 903 812 1018 416 1400 614 1620 812 1850
B31-3 586 788 869 903 586 1400 869 1620
B31-4 754 788 754 1400
B31-5 924 788 472 1160 924 1400
B31B-2 368 788 542 903 716 1018 368 1400 542 1620 716 1850
B31B-3 514 788 761 903 514 1400 761 1620
B31B-4 658 788 977 903 658 1400 977 1620
B31B-5 804 788 804 1400
B32-2 304 788 446 903 588 1018 304 1400 446 1620 588 1850

B41-2 416 844 614 959 812 1074 416 1550 614 1800 812 2050 SINGLE TIER RACKS
B41-3 586 844 869 959 586 1550 869 1800 3STEP 1TIER RACK

B41-4 754 844 754 1550

B41-5 924 844 472 1320 924 1550
B41-6 557 729 1094 844 557 1320

B41B-2 368 844 542 959 716 1074 368 1550 542 1800 716 2050
B41B-3 514 844 761 959 514 1550 761 1800
B41B-4 658 844 977 959 658 1550 977 1800
B41B-5 804 844 804 1550
B42A-2 290 884 425 959 560 1074 290 1550 425 1800 560 2050
B42-2 304 884 446 959 588 1074 304 1550 446 1800 588 2050
B42-6 782 884 782 1550
(All dimensions in mm)

Calculation of length :
Length of rack = (X + 5) x No. of block cells in a row ( for all block cells )
Where X = Length of cell / Block cell for Row-wise mounting ( i.e. for B21-1, B22-1,B23-1, B24-1, B31-1, B31B-1,
B32-1, B33-1, B41-1, B41B-1, B42-1, B42A-1, B44-1, B45-1)
= width of Cell / Block cell for Cross-wise mounting ( i.e. for B31 / 31B / 32 / 41 / 41B / 42A / 42-2 / 3 / 4 / 5 / 6)
The value of length should be rounded-off to nearest to 50 mm and 5mm should be added.

Standard arrangement of cells on racks :

Arrangement KBH KBM KBL

Normal 9 to 118 12 to 231 8 to 256

Crosswise 127 to 930 277 to 1460 280 to 1540

SINGLE TIER RACKS

4STEP 1TIER RACK

NORMAL ARRANGEMENT CROSS WISE ARRANGEMENT

Optional Items :
(To be supplied on request)
1. Cubicles in place of racks
2. Low electrolyte level / alarm
3. Containers in structural foam molded polypropylene
4. Stainless / Wooden / HDPE crates for cells
5. Recombination vents

31
 TWO TIER RACKS TWO TIER RACKS
1STEP 2TIER RACK 2STEP 2TIER RACK

TWO TIER RACKS TWO TIER RACKS

3STEP 2TIER RACK 4STEP 2TIER RACK
 Typical Characteristics

KBL Charging Voltage

Charge KBL Discharge

1. 1.40 Volts / Cell

Amp. % 2. 1.45 Volts / Cell
3. 1.50 Volts / Cell
I/C 4. 1.55 Volts / Cell
5. 1.60 Volts / Cell
6. 1.65 Volts / Cell Volts/Cell
6
7. 1.70 Volts / Cell 7
Available Capacity % 1.4
0.2 100
5
1.3
4
3
1.2
2
2 1 1.1
7 1.0
0.1C5A
4 0.2C5A
0.9
0.1 50 5 0.5C5A
3 0.8
Current
0.7 1C5A
6
1
0.6

0.5
10 20 30 40 50 60 70 80 90 100

1 2 5 10 20 50 Hours
% in Capacity

KBM Charging Voltage

Charge KBM Discharge

1. 1.40 Volts / Cell

Amp. % 2. 1.45 Volts / Cell
3. 1.50 Volts / Cell
4. 1.55 Volts / Cell
I/C
5. 1.60 Volts / Cell 7
6. 1.65 Volts / Cell 6 Volts/Cell
7. 1.70 Volts / Cell Available Capacity % 2 3 4
7 5 1.4
0.2 100 1.3

1 1.2

1.1

1.0 0.1C5A
1 0.2C5A
2
0.9 0.5C5A

0.8 1C5A
0.1 50
6
0.7

0.6
4 2C5A
5 0.5
10 20 30 40 50 60 70 80 90 100
Current
3

1 2 5 10 20 50 Hours % in Capacity

KBH Charging Voltage

Charge KBH Discharge

1. 1.40 Volts / Cell

Amp. %
2. 1.45 Volts / Cell
3. 1.50 Volts / Cell
4. 1.55 Volts / Cell
I/C
5. 1.60 Volts / Cell 7 6 Volts/Cell
6. 1.65 Volts / Cell 1 2 3 4 1.4
7. 1.70 Volts / Cell 5 Available Capacity %
7
1.3
0.2 100
1.2

6 1.1
1
4 1.0
0.2C5A
0.5C5A
2 0.9 1C5A
5
2C5A
0.8
0.1 50 3C5A
0.7
Current
0.6 5C5A

0.5
3
10 20 30 40 50 60 70 80 90 100

1 2 5 10 20 50 Hours % in Capacity
 corp.comm\10-2006

HBL Power Systems Limited

Road # 10, Banjara Hills, Hyderabad - 500 034. INDIA
E-mail: contact@hbl.in
www.hbl.in
 Doc. Ref.
PEE/P 3182 LIST
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 1 of 1

RECTIFIER DIVISION
LIST OF DRAWINGS/DOCUMENTS

CUSTOMER : M/S. BHEL , BANGALORE

PROJECT : NTPC- VALLUR UNIT 1,2
PO No. : 4000025934 DATED:12.10.09
JOB NO. : TP-09-1 3182
TYPE OF UNIT : 12 SP 105 CELL BOOSTER
(TG CHARGER FOR UNIT-I,2)
QUANTITY 1 No PER UNIT.

Prepared: Checked: Approved:

S.NO DESCR IPTION DOCUMENTNO NO.OF REV

SHEETS

1. SYSTEM DESCRIPTION FOR CELL BOOSTER PEE/P84292 1 0

2. TECHNICAL SPECFICATION FOR PEE/P88292 2 0

CELLBOOSTER
3. BILL OF MATERIAL FOR CELLBOOSTER PEE/P81292 2 0

4. GENERAL ARRANGEMENT DRAWING FOR PEE/P90137A 1 0

CELLBOOSTER
5. ELECTRICAL SCHEMATIC FOR PEE/P51292 1 0
CELLBOOSTER
 Doc. Ref.
PEE/P 84292
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 1 of 1

RECTIFIER DIVISION
SYSTEM DESCRIPTION

CUSTOMER : M/S. BHEL , BANGALORE

PROJECT : NTPC- VALLUR UNIT 1,2
PO No. : 4000025934 DATED:12.10.09
JOB NO. : TP-09-1 3182
TYPE OF UNIT : 12 SP 105 CELL BOOSTER
(TG CHARGER FOR UNIT-I,2)
QUANTITY : 1 No PER UNIT.

Prepared: DEEPAK Checked: DRK Approved: HSB

SYSTEM CONFIGURATION :

Cell Booster is a simple charger, used to boost charge the new & sick cells for revival of the cell. The 7 Nos
of Ni-Cd Cells will be charged upto 1.7V/cell and at a current of 0.2C. The cell shall be charged till it
reaches 1.7V/cell.

The Cell Booster is built in a separate portable panel. It has a thyristorised full wave half controlled bridge
consisting of thyristors and diodes.

On the AC side of the Cell Booster, an input ON / OFF switch with fuses and Input On LED has been
provided. An input voltmeter has been provided to read the I/P voltage.

On DC side of the cell booster Output ON/OFF switch with fuses is provided. A separate Voltmeter and
Ammeter are provided at the output side of the Cell Booster to read the output voltage and output current.
On the DC side Output ON LED is provided.

Potentiometers PT1 and PT2 are provided to adjust the output voltage and current respectively.

OPERATION:

Set the output voltage with potentiometer(PT1) acording to number of cells to be connected for charging
i.e. 1.7V X no.of cells. Connect the cells to cell booster with correct polarity. Switch on the charger & set
current for charging the cells with potentiometer(PT2).
 Doc. Ref.
PEE/P 88292
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 1 of 2

RECTIFIER DIVISION
TECHNICAL SPECIFICATION

CUSTOMER : M/S. BHEL , BANGALORE

PROJECT : NTPC- VALLUR UNIT 1,2
PO No. : 4000025934 DATED:12.10.09
JOB NO. : TP-09-1 3182
TYPE OF UNIT : 12 SP 105 CELL BOOSTER
(TG CHARGER FOR UNIT-I,2)
QUANTITY 1 No PER UNIT.

Prepared: DEEPAK Checked: DRK Approved: HSB

SR. NO. PARAMETER SPECIFICATION

1 AC input voltage 240V ± 10%, 1 phase, 3 wire

2 AC input frequency 50 Hz ± 5%

3 DC output voltage settings: 12V (0-12V ADJ)

4 Output Current Limit 105A

5 Power Conversion AC to DC by means of a single phase full wave half

Controlled Bridge consisting of Thyristors and diode.

6 Output Voltage Regulation ±1V for ±10% input voltage variations, and ±3%
frequency variations for 5-100% load variations.

7 Ripple voltage < 5% RMS (Without battery connected)

8 Switchgear:
a) Input side SWITCH + FUSE
b) Output side SWITCH + FUSE

9 Protection Current limit protection, Soft start

Control circuit fuses
For voltage & current adjustment
10 METERS (72 x 72 Sqmm 2.5%ACC)
I/P VOLTMETER
O/P AMMETER
O/P VOLTMETER
11 INDICATIONS I/P ON LED
O/P ON LED
 Doc. Ref.
PEE/P 88292
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 2 of 2

12 Operating Temperature 50° C (Surrounding the panel)

13 PANEL
Dimensions 1050H X 800W X 600D
Protection Grade IP- 42
Paint shade RAL 9002

14 MAGNETICS
Insulation class Class F
Average winding temp. Rise over 90 Deg. C
ambient
Insulation break down voltage 2KV for 1 Min
Type of cooling Natural air cooling

15 CABLES: 1100V grade PVC insulated copper cables are used.

Doc. Ref.
PEE/P 84292
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 1 of 2

RECTIFIER DIVISION
BILL OF MATERIAL

CUSTOMER: M/s BHEL , BANGALORE.

PROJECT: NTPC - VALLUR UNIT 1,2
CUTOMER P.O. NO: 4000025934 Dt:12.10.09

TYPE OF UNIT 12 SP 105 CELL BOOSTER (TG CHARGER FOR UNIT-I,2)

JOB NO: TP 09-01-3182

QUANTITY 1 NO PER UNIT

PREP: CHECKED BY: APPR BY:
SL .NO. PART NO. DESCRIPTION SPECIFICATION MAKE QTY.
1 CONSOLE 1050H X 800W X 600D HBL 1
TRANSFORMERS & CHOKES
T1 MAIN TRANSFORMERS 2.79 kVA HBLEMD
PRI: 240 ±10%, 11.61A
1 SEC1: 22V, 128.10A 1
SEC2: 0-20V, 1A
SEC3: 0-20V, 1A
6 L1 CHOKE 0.27mH AT 105A DC 1
CAPACITORS
C1 FILTER CAPACITORS 47000 MFD/40V DC SARADA/ALCON/
9 (5 IN PARELLAL) 5
RESCON
RECTIFIERS & HEATSINKS
THYRISTORS WITH 200A, 600V PIV HIRECT/RIR/IR/ IXYS
1 V1, V2 SUITABLE HEATSINK HS:EIA 1717 150MM 2

V3, V4 DIODES,WITH SUITABLE 200A, 600V PIV

2 HEATSINK HS:EIA 1717 225MM 2

SWITCHES
S1 I/P ON/ OFF SWITCH 25A, 2P, AC ON/OFF SWITCH
1 KAYCEE/ L&T/SCI 1

S2 O/P ON/ OFF SWITCH 200A, 2P, DC ON/OFF SWITCH

2 KAYCEE/ L&T/SCI 1

METERS & SHUNTS:-72 sqmm 90deg deflection accuracy class 2.5%

1 P1 I/P VOLTMETER 0-300V AC 1
2 P2 0/P VOLTMETER 0-25V DC 1
RISHABH/AE/IMP/
3 P3 O/P AMMETER 0-150A, DC UBAH 1
4 SH1 SHUNT 150A, 75m V 1
FUSES
F1, F2 INPUT FUSES 25A, WITH SUITABLE FUSE BASE
1 GE/BUSSMAN 2

F3 CAPACITOR FUSE 100A FUSE WITH SUITABLE BASE

2 GE/BUSSMAN 1

F4-6 VOLTMETER FUSES TERMINALS WITH 1A GLASS

3 FUSES CW 3

F7-8 RECTIFIER FUSES 200A HRC BOLTED TYPE

4 GE/BUSSMAN 2

F9-10 OUTPUT FUSES 160A FUSE WITH SUITABLE BASE

5 GE/BUSSMAN 2
Doc. Ref.
PEE/P 84292
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 1 of 2

SL .NO. PART NO. DESCRIPTION SPECIFICATION MAKE QTY.

ELECTRONICS CARDS
1 A1 RC CARD 69-00001 (12V) HBL 1
2 A2 CONTROL CARD 69-00149 1
INDICATING LED & POTENTIOMETERS
VD1 INPUT ON LED 10 mm RED LED WITH METAL REPUTED
1 HOLDER 1

VD2 OUTPUT ON LED 10 mm RED LED WITH METAL

2 1
HOLDER
PT1, 2 POTENTIOMETERS 20K MULTI TURNS BOURNS
3 2

CABLES
1 INPUT WIRING 4 Sq.mm HAVELLS
2 OUTPUT WIRING 20 X 3 CU BUSBAR REPUTED
3 CAPACITOR WIRING 15 X 3 CU BUSBAR REPUTED
4 CONTROL WIRING 2.5 Sq.mm (GREY & BLACK) HAVELLS
5 PCB WIRING 0.5 Sq.mm (GREY & BLACK) HAVELLS
6 EARTHING BUS-BAR 25 x 3 mm CU BUSBAR REPUTED
TERMINALS
1 X/1-3 INPUT TERMINALS CSTS N6 C.W 3
2 X/4,5 OUTPUT TERMINALS M10 X 70L REPUTED 2
 Doc. Ref.
PEE/P 3182 LIST
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 1 of 1

RECTIFIER DIVISION
LIST OF DRAWINGS/ DOCUMENTS

CUSTOMER : M/S. BHEL , BANGALORE

PROJECT : NTPC- VALLUR UNIT 1,2
PO No. : 4000025934 DATED:12.10.09
JOB NO. : TP-09-1 3182
TYPE OF UNIT : 20-35V/135A DISCHARGE RESISTOR PANEL
(TG CHARGER FOR UNIT-I,2)
QUANTITY : 1 No PER UNIT.

Prepared: Checked: Approved:

S.NO DESCR IPTION DOCUMENTNO NO.OF REV

SHEETS

1. SYSTEM DESCRIPTION PEE/P84292D 2 0

2. TECHNICAL SPECFICATION PEE/P88292D 2 0

3. BILL OF MATERIAL PEE/P81292D 2 0

4. GENERAL ARRANGEMENT DRAWING PEE/P90139A 1 0

5. ELECTRICAL SCHEMATIC PEE/P51292 1 0

 Doc. Ref.
PEE/P 84292D
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 1 of 2

RECTIFIER DIVISION
SYSTEM DESCRIPTION

CUSTOMER : M/S. BHEL , BANGALORE

PROJECT : NTPC- VALLUR UNIT 1,2
PO No. : 4000025934 DATED:12.10.09
JOB NO. : TP-09-1 3182
TYPE OF UNIT : 20-35V/135A DISCHARGE RESISTOR PANEL
(TG CHARGER FOR UNIT-I,2)
QUANTITY : 1 No PER UNIT.

Prepared: Checked: Approved:

Introduction: -

The HBL Electronic Discharge Banks are manufactured using Solid-state devices such as IGBT’s.
Usage of this Power Electronic Control device extends the flexibility of Battery discharge at
constant current irrespective of the battery discharge voltage.

IGBT (Insulated Gate Bi-polar Transistor), Diode, and Inductor & Resistor in conjunction with
Control & Switching circuit are used in Discharger to maintain the Constant Current when it’s
Discharging Battery.

Given below is the basic block Diagram of the System: -

DC Input Current Switching Storage

Load
Sensing Device Filter/Free
C.T (IGBT) wheeling
Diode

Control
Circuit
Doc. Ref.
PEE/P 84292D
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 2 of 2

ELECTRONIC BATTERY DISCHARGE BANK

1) The electronic load bank has been designed to operate with various battery systems and
is extremely cost effective.
2) The Load Bank has Constant Current/Constant Voltage operation. The load current is
continuously variable over the entire current range. The current can be controlled from
front panel.
3) The electronic Load Bank now becomes an intelligent load; it prevents deep discharge of
the batteries and hence prevents any possible damage to them.

Features: -
1) Rugged and reliable design.
2) Compact in size, lightweight.
3) Constant Voltage and Constant Current modes.
4) Thermally safe.
5) Prevents Battery deep discharge.
 Doc. Ref.
PEE/P 88292D
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 1 of 2

RECTIFIER DIVISION
TECHNICAL SPECIFICATION

CUSTOMER : M/S. BHEL , BANGALORE

PROJECT : NTPC- VALLUR UNIT 1,2
PO No. : 4000025934 DATED:12.10.09
JOB NO. : TP-09-1 3182
TYPE OF UNIT : 20-35V/135A DISCHARGE RESISTOR PANEL
(TG CHARGER FOR UNIT-I,2)
QUANTITY : 1 No PER UNIT.

Prepared: Checked: Approved:

BATTERY DISCHARGE PANEL – 20V-35V, 135A

Input : 20V-35VDC
Rating : 135A
Mode of operation : Constant Current
Topology : IGBT Based Buck Converter
Dimensions : 1700H X 800W X 600D

Protection grade : IP-21

Finishing : RAL 9002
Cooling : Forced Air

Power supply unit:

Supply voltage : 220Volts AC

Phase : Single Phase
Power Consumption : 100VA Max
Frequency : 48 – 52Hz

Battery Input :

Voltage : 20V – 35V DC

Current : 0A – 135A
Current Regulation : Better than 2%
Max Load Power : 7.5 kw

Protections :

1. Battery Reverse Polarity : Alarm and Indication Provided

2. Over Current : applicable
3. Over Voltage : applicable
4. Under Voltage : applicable
5. Input side : MCB Provided
 Doc. Ref.
PEE/P 88292D
No.
Rev. No. 0
Date 21.10.09 HBL Power Systems Ltd.
Sheet 2 of 2

Controls :
1. 10 turn Pot for Discharge Current
2. Start/Stop
Display :

Digital Voltmeter for Battery Voltage

Digital Ammeter for Discharge Current

AC Supply Lead : Two meter long with 3-pin Plug.

DC Labels : Bus Bar Connector
Environmental
Temperature : 0 - 50˚C
Altitude : 0 – 1000mtrs

LED alarms for Faults

VD1 : SYSTEM ON
VD2 : SYSTEM TRIP
VD3 : BATTERY REVERSE
 HBL POWER SYSTEMS LTD
REF NO.PEE/P 81292D
REV 0.DATE 21.10.09
PAGE 1 OF 2
RECTIFIER DIVISION
BILL OF MATERIAL

CUSTOMER: M/s BHEL , BANGALORE.

PROJECT: NTPC - VALLUR UNIT 1,2
CUTOMER P.O. NO: 4000025934 Dt:12.10.09
TYPE OF UNIT 20V-35V/135A DISCHARGE RESISTOR PANEL (TG CHARGER FOR UNIT-I,2)
JOB NO TP 09-01-3182
QUANTITY 1 NO PER UNIT
PREP: CHECKED BY: APPROVED BY:
SL .NO. PART NO. SPECIFICATION MAKE QTY.
1 CONSOLE 1700H X 800W X 600D HBL 1
2 C1 47000 MFD/63V DC (3 IN PARALLEL) RESCON/ALCON 3
3 Q1 200A DC ON/OFF MCCB SCHNEIDER/ABB 1
4 Q2 6A, 2P AC ON/OFF MCB SCHNEIDER/ABB 1
IGBT1 300A, 1200V PIV EUPEC
5 1

HP1 HALL PROBE 200A PTIC

6 1
SH1 200A/ 75mV UBAH/IMP/AE
7 1

P2 (DAM) 0-200A DC, 31/2D 1% ACC, 48X96mm, CANDEL/ RATO

8 1
AUX.100V-300V AC
P1 (DVM) 0-100V DC, 31/2D 1% ACC, 48X96mm, CANDEL/ RATO
9 1
AUX.180V-300V AC
10 L1 0.3mH AT 200A DC HBL 1
11 R1 24V/ 200A IRESCO ELECTRICAL 1
12 HS1 HEAT SINK 80AD-200mm EIA 1
13 FAN1, 2 230V, 35W AC AXIL - 2 NO'S RENNORD 1
14 C3 1MF/1000V BOX CAP ALCON/RESCON 1
15 T1 20VA,PRI: 230V ±10%,SEC: 18-0-18V. HBL 1
16 T2 20VA,PRI: 230V ±10%,SEC1: 0-20, SEC2: 0-20. HBL 1
17 BZ1 BUZZER 12V DC KELTRON 1
PT1 20K MULTI TURNS POT WITH KNOB BOURNS
18 1

19 PB1 MPS-1, 4A, 1NO, GREEN PBS ELCON 1

20 PB2 MPS-1, 4A, 1NO, RED PBS ELCON 1
RL1 24V DC, 3C/O MCC RELAY WITH BASE OEN/PLA/L&T
21 1

22 VD1,2,3 5mm RED LED KWALITY 3

F1 1A GLASS FUSE WITH HOLDER C.W
23 1

24 A1 CONTROL CARD (69-00358) HBL 1

25 A2 DRIVER CARD (69-00357) HBL 1
J1, J7, J10 3 PINALEX FEMALE CONNECTOR WITH PINS ALEX
26 3

J3, J5 9 PINALEX FEMALE CONNECTOR WITH PINS ALEX

27 2

J4, J8, J12 4 PINALEX FEMALE CONNECTOR WITH PINS ALEX

28 3

J6, J13 7 PINALEX FEMALE CONNECTOR WITH PINS ALEX

29 2

J2, J11 5 PINALEX FEMALE CONNECTOR WITH PINS ALEX

30 2
 HBL POWER SYSTEMS LTD
REF NO.PEE/P 81292D
REV 0.DATE 21.10.09
PAGE 2 OF 2
SL .NO. PART NO. SPECIFICATION MAKE QTY.
CABLES
31 INPUT WIRING 2.5 Sq.mm HAVELL'S
OUTPUT 25 X 5 CU BUSBAR HAVELL'S
32 WIRING
CAPACITOR 25 X 5 CU BUSBAR HAVELL'S
33 WIRING
CONTROL 2.5 Sq.mm (GREY & BLACK) HAVELL'S
34 WIRING
35 PCB WIRING 0.5 Sq.mm (GREY & BLACK) HAVELL'S
EARTHING 25 x 3 mm CU BUSBAR REPUTED
36 BUS-BAR
TERMINALS
37 X/1-2 M12 X 70L REPUTED/C.W 2
38 X/3,4 M12 X 70L REPUTED 2